Reconstruction of pelvic bone defect after resection for bone tumours is a challenging procedure especially when the hip joint is involved due to the anatomy and the complex biomechanical and structural function of the pelvic ring. This surgery is associated to high complication rate. The additive 3D printing technology allows us to produce trabecular titanium custom based implants with an accurate planning of resection using bone cutting jigs.

From August 2013 to January 2017, we treated 8 patients for bone pelvic sarcoma with custom-made osteotomy jigs (Nylon) and custom-made trabecular titanium prosthesis produced through rapid prototyping technology based on mirroring of the contralateral hemipelvis. Mean follow up time was 18 months (range 2–30) Wide margins were obtained in all cases, in one a local recurrence developed. Surgical time was 4 hours average (from 180 to 250 mins). No postoperative complications were reported.

Rapid prototyping is a promising technique in order to achieve wide surgical margins and restore the anatomy in pelvic bone tumour resection as well as reducing complications.